System for the sonic treatment of emulsions and for resolving the same into their constituent parts



Aug.- 17, 1965 v R. D. MAY 3,200,567

. SYSTEM FOR THE SONIC TREATMENT OF EMULSIONS AND FOR RESOLVING THE SAMEINTO THEIR CONSTITUENT PARTS Filed Sept. '7, 1956 2 Sheets-Sheet 1 FIG.I 4) w 7 2/ FIG. 2 0

INVENTOR Russell D. May

ATTORNEY Aug. 17, 1965 MAY 3,290,567

SYR'IEM FOR THE some TREATMENT OF EMULSIONS AND FOR RESOLVING THE SAMEINTO THEIR CONSTITUENT PARTS Filed f2pt. '7, 1956 2 Sheets- Sheet 2Russell D. May

M ATTORNEY;-

United States Patent SYSTEM FUR THE SQNIC TREATMENT OF EMUL- SIGNS ANDFUR RESQLVING THE SAME INTO THEIR CONSTITUENT PARTS Russell Denton May,Tulsa, Okla, assignor, by mesne assignments, to Black Sivalls & Eryson,Inc, Kansas City, M0., a corporation of'Delaware Filed Sept. 7, 1956,Ser. No. 608,626 4 Claims. (Cl. 55--175) The present application is acontinuation-in-part of my application Serial No. 425,523, filed April26, 1954, now US. Patent No. 2,864,502.

The present invention relates to ultra-sonic means for resolvingoil-water emulsions in a continuous flow treatment.

A primary object of this invention is the provision of means for thecontinuous flow treatment of oil-water petroleum emulsions within anultra-sonic electroacoustic transducer at a cavitation area axiallywithin the flow line of the emulsion in the transducer for breaking theemulsion and freeing water in the vapor phase.

A further object of this invention is the provision of a continuous flowtreatment of an oil-water emulsion under such circumstances as toprovide for an etficient, economical and commercially acceptable processwhich will result in substantially complete dehydration of the emulsion.

A further object of this invention is the provision of a process for thesonic or ultra-sonic vibrational treatment of hydrocarbon emulsions atapproximately the cavitational level within the instantaneous volume ofoil being treated. Afuither object of this invention is the provision ofa system of treating oil-water petroleum emulsions in an electroacoustictransducer having transducer elements operated by high frequencyelectrical power wherein the emulsions are subjected to radiated soundso focused as to enable the rapid breaking of the emulsion wherein thewater is separated in the vapor phase; resulting in a substantiallydehydrated product.

Other objects and advantages of this invention will be apparent duringthe course of the following detailed description.

In the accompanying drawings forming a part of this specification, andwherein similar reference characters designate corresponding partsthroughout the several views:

FIGURE 1 is a side elevation, partly in section, showing one form ofelectroacoustic transducer.

FIGURE 2 is a longitudinal cross sectional view taken through theelectroacoustic transducer of FIGURE 1.

FIGURE 3 is a cross sectional view taken substantially on the line 3-3of FIGURE 2.

FIGURE 4 is a fragmentary side elevation of a multiple stage system forresolving of hydrocarbon emulsions wherein an ultra-sonicelectroacoustic transducer for breaking the emulsions is used.

FIGURE 5 is a side elevation of another of multiple stage systems, suchas set forth in my US. Patent 2,864,- 502, dated December 16, 1958, andwherein an ultra-sonic electroacoustic transducer may be used in theline between the heater and separator stages to assist in breakingemulsions.

FIGURE 6 is a side elevation of still another multiple stage treatingapparatus for resolving hydrocarbon emulsions substantially as set forthin detail in my US. Patent 2,864,502, dated December 16, 1958 andwherein an electroacoustic transducer is shown as applied between thefreewater knockout and a heater stage.

FIGURE 7 is a view showing the electroacoustic transducer in a flow linefor breaking hydrocarbon emulsions and in which system a vapor and gastrap may be used as well as a storage tank for the separated liquids.

3,200,567 Patented Aug. 17, 1965 The multiple stage units shown inFIGURES 4, 5 and 6 are substantially of the type specifically describedin my U.S. Patent 2,864,502, dated December 16, 1958, and furtheramplified and described in detail in my co-pending applications SerialNo. 608,624, filed July 7, 1956, now

US. Patent No. 2,996,188; Serial No. 584,818, filed May 14, 1956, nowUS. Patent No. 3,040,499, and. Serial No. 608,625, filed September 7,1956, now US. Patent No. 3,035,701.

One form of eletcroacoustic transducer is shown in my US. Patent2,864,502, dated December 16, 1958, but the form of transducer A shownin FIGURES 1, 2 and 3 of the present application is modified thereover.

The transducer A preferably comprises a casing structure 10, consistingof end plates 11 and 12 to which axially aligned end stub pipes orextensions 13 and 14 are respectively connected, as by welding. Theextreme ends of these pipes 13 and 14 are externally screw threaded forreceiving coupling flanges 15 and 16 adapted to be connected'as by bolts17 to a pipe line 18 in which the electroacoustic transducer is to beused. Preferably the axis of the transducer as installed will be on avertical axis, although in some instances the axis may be horizontal orat an angle to the vertical.

The structure 10 is a protecting anddust excluding casing which includessemi-cylindrical wall portions 20 and 21 which may be flanged atopposite sides and secured together by means of bolts 23. Their ends maybe secured as by machine screws or bolts 25 to the end plates 11 and 12,as shown in FIGURE 2.

A flow casing is provided for supporting the transducer elements. It maybe constructed of any suitable material which will best withstand theeffects of. the emulsion being treated and vibrational shocks. Its endsmay be countersunk and welded to the inner walls of the end plates 11and 12, as shown in FIGURE 2.

The tubular casing 30 is preferably provided with openings therein, eachextending about 90 around the circumference of the casing 30. They arecircumferentially positioned on centers about 90 apart and staggeredlongitudinally of the casing 30, as shown in the drawings. Each of thesame receives, in liquid sealed relation therein, transducer elements orvibrating members 41. They are arcuate in shape and each is sealedexternally upon the casing 30 at the ends of the are by gaskets 42 andalong the arcuate margins thereof by other gaskets 43. These elements 41may be held in place by adjustable flexible straps 44 having lengthadjustment means 45 therein. Space supporting blocks 46 at each end of atransducer element support the straps. Two of these straps are providedfor each transducer member or element 41, as shown in the drawings.Where the straps engage the transducer element, they may rest upongaskets or pads 47 to prevent injury to the transducer elements.

The centers of the radii from which the arcs of the transducer elementsare struck lies in the axial line of the passageway 48 through the tubeor casing 30. The plate 12 may support a conductor cable for transmittalof electrical energy to the surface electrodes (not shown) of thetransducer elements 41.

The transducer elements .41 are preferably constructed of bariumtitanate, although other thickness expanders may be used if desired.Preferably they have a thickness mode resonance of approximately 200 kc.They are coated, particularly upon the inside or concave surfacesthereof with glazed surfaces impervious to practically all liquids,including all common acids. This makes possible the elimination of therubber sound window of the elec troacoustic transducer which is shown inmy US. Patent 2,864,502, dated December 16, 1958, and enables thetransducer to function with an increased acoustic power. Thesetransducer elements are capable of handling power 3 to the extent thatthe soundintensity of the focus is approximately 160 dbs above one dyneper square centimeter.

The focal area within the casing 30 exhibits cavitation in a cylindricalsection of chamber 48 of a predetermined diameter which may vary withthe size of the transducer. Within the area of cavitation the vibrationsof the transducer elements will release water from the oil in the formof water vapor, in free bubble form. It'may be released either directlyfrom the transducer or in the linepast the transducer;

The emulsifying vibrations may be obtained by magnetostriction or evenby mechanical vibrating generators if such are practical for thatpurpose. I do not desire to be limited to specific frequencies althoughthe results desired are obtainable by frequencies of from 200 kc. to 400kc. If lower and higher frequencies of vibration are desired, I may useother vibrating means than the transducer elements herein specificallydescribed. The sound intensity at the focus must be above thecavitational level.

The amplitude of vibrations of the transducer'elements should besufficient to cause cavitation within an appreciable sized core of theemulsion being treated in the transducer. 'In other words, the soundintensity at the focus must be above the cavitational level.

As to the electric power needed for excitement of the speed, or ifdesired some means may be provided for intermittently trappingthehydrocarbon emulsion in the transducer for a predetermined period oftreatment and then I passed into the flow line 18. Water released in thevapor phase may be withdrawn directly from the transducer or in the flowline 18 in advance of the transducer. In one such form, shown in FIGURE7, I may provide a vapor trap 51) in the flow line 18 for releasing bothwater and gas vapors, which may later be condensed and separated in anyapproved manner. Line 18 may deposit the emulsified product into asuitable storage tank 51 wherein a water drawoif line 52 having anautomaticall operated release valve 53 may be used. An oil drawoff line54; may be provided in the tank 51-having a pressure regulating valve 55therein in the event it is desired to maintain superatmosphericpressuresin the storage tank 51'. The valve 53 may be float actuated by a torquetube liquid level control; the float operating at the interface betweenthe demulsified oil and water Within the tank 51. gas and vapor take-off50 may be provided with a pressure regulating valve 61 therein ifdesired.

It may be desirable in a system utilizing a storage tank for receivingthe agglomerated products from the electroacoustic transducer to permitsuch products toremain in such tank a sufficient time period foroptimum'oil and water separation.

The system of FIGURE 7 can be operated with its contentsunderatmospheric pressure if desired.

Referring to FIGURE 4, the electroacoustic transducer Amaybeplaced inpipe connection 18 leading between a free water knockout B of the typedescribed in the aforesaid U.S. Patent and co-pending applications and aseparation tank C, or the electroacoustic transducer A, as shown inFIGURE 5 may be used in a multiple stage treatment which includes a freewater knockout B, heater stage D and separation stage C. The transducerA may be used in a multiple stage system, as shown in FIGURE 6 between afree water knockout B and a heater D either with or without a separationstage C 7 The free water knockout heater and separator stages of FIGURES4, 5 and 6 are specifically disclosed as to structure and functioning inmy U.S. Patent 2,864,502, dated and separating The 4 December 16, 1958,and in co-pending applications, Serial No. 608,624, filed July. 7, 1956,Serial No. 584,818,

filed May 14, 1956 and Serial No. 608,625, filed Septemher 7, 1956.

In FIGURE 4 the free water knockout B is intended to separate any freewater from the oil to be treated. It includes a tank 70 having a chamber71 therein with a partition 72 subdividing the chamber 71 into an uppercompartment 73, and a lower compartment 74. The emulsified productenters the compartment 72 through a line 75 and passes downwardlythrough a tube 76 out of perforations in said tube onto a lateraldistributing or deflector pan 78 which distributes, the emulsion andwater for best separating the free Water. The free water drops into thebottom of the compartment 74 and is discharged through a line 79externally of the tank. The line '79 externally of the tank is providedwith an automatically operated valve 80 which by means of a torque tubeliquid level control 81 is opened and closed; its float 82 operating atthe interface between the emulsion and the free water. The emulsifiedoil enters the upper end of a discharge tube 84 which leads downwardlyand outwardly into pipe 18 for passing the emulsified product into theelectroacoustic transducer A, with the result above described. Thedemulsified product is passed from the electroacoustic transducer Ainto' the separator C through a perforated nozzle 90. i

The separator C is of the type described in my above identifiedco-pending applications, including filter packs 91 and 92 subdividingthe chamber of the tank 93 into a lower compartment 94; an intermediatecompartment 95 and an upper compartment 96. A water'discharge line 97leads from the bottom compartment 94 to externally of the tank where itis provided with a valve and torque tube liquid level control 98; thefloat '99 "of the latter operating at the interface between oil andwater in the compartment 95. This separator tankC is shown by way ofexample. Other means may be -provided for cleaning the constituent partsof the demulsified product.

As shown .in FIGURE 5 it'may be desirable toinitially heat thedemulsified product after the knockout of free water in the stage B Theemulsified product is initially broken in the .tank B and treated forfurther separation in the electroa-coustic transducer A, which ispositioned in a line 18 leading from the heater D to the separationstage C. For some types of hydrocarbon emulsions, it may be necessary toplace the electroacoustic transducer A in advance of the heater tank andto that end it may [be located in an emulsion line 18 leading from thewater knockout B as shown in FIGURE 6 and then passed into the heater D,and subsequently if desired the demulsified product may be treated forseparation in a stage C In the multiple stage treatments of FIGURES 4 to6 inclusive, superatmospheric pressures may befmaintained upon theemulsion to be treated throughout all of the stages and in thetransducer A if desired or the system may be operated at substantiallyatmospheric pressure.

Flow speed and time of treatment in the electroacoustic transducer areimportant in order to prevent re-emulsification of the oil and water.

The transducer elements are preferably so focused in the electroacoustictransducer as to provide for cavitational levels of sound inapproximately 50% of the oilwater being treated at any particularinstant. For that reasonthe four transducer elements 41 are arranged' incylindrical fashion. Such, arrangement was determined by the rate of Howof oil in the chamber and an estimate of the time of treatment requiredper unit volume. Higher rates'of flow can be accommodated by using agreater number of transducer elements,'and itmaybe possible to usefewertransducer elements for lower rates of liquid flow.

I do not desire to be restricted to a cylindrical type of transducer,since it may be possible to use a hemispherical focusing element orother shapes; depending upon the configuration of the chamber in whichthe emulsion is to be treated. If higher driving powers can betolerated, the necesary cavitational levels could be achieved by planesurface transducers without recourse to focus- It will be noted that thetransducers of FIGS. 4, 5, 6 and 7 are vertically positioned. This isfor the reason that the entire transducer must be completely full ofliquid during operation, in order to secure the best separating and bestfocusing vibrations.

Various changes in the shape, size and arrangement of parts, andvariations in the steps of sonic and ultra-sonic treatment of emulsionsmay be made to the form of invention herein shown and described withoutdeparting from the spirit of the invention or scope of the claims.

I claim:

1. Apparatus for the separation of hydrocarbon emulsions comprising aheater for receiving hydrocarbon emulsions, means in the heater forbreaking the emulsions to a substantial extent, a filter tank, meansconnecting the heater tank with the filter tank for flow of oil from theheater tank to the filter tank, means in the filter tank for filteringwater from the oil therein, and means connected between the two tanksfor treating the products received from the heater tank with ultra-sonicdemulsi- -fying vibrations at approximately the cavitation level in theinstant volume of oil flowing from the heater tank to the filter tank.

2. Apparatus for the treatment of hydrocarbon emulsions for resolvingthem into their constituent water, oil and gas parts comprising meansfor knockout of free water from the emulsified hydrocarbon, heater meansfor heating the emulsified product, means for subsequently filtering theproduct from the heater means, and means for treating the hydrocarbonproduct as it flows from the heater means to the filter means withultra-sonic demulsifying vibrations at approximately the cavitationlevel.

3. A multiple stage treatment for resolving hydrocarbon emulsions intothe constituents parts comprising means for free water knockout of Waterfrom the emulsified hydrocarbon product, heater means for heating theemulsified product to substantially reduce the emulsification of thehydrocarbon product, means to filter the hydrocarbon product of theheater means for the removal of free Water from oil, and means betweenthe free Water knockout and the heater means to subject the emulsionpassing to the heater means with ultra-sonic demuls-itying vibrations atapproximately the cavitation level.

4-. A multiple stage treatment apparatus for resolving hydrocarbonemulsions comprising a free Water knockout for treating hydrocarbonemulsions for removal of free water therefrom, a heater means forreceiving the hydrocarbon product from the free water knockout andheating the same for substantially breaking the hydrocarbon emulsion,filter means for receiving the hydrocarbon product from the heater meansfor separation of free water from oil, and means for treating thehydrocarbon product between the free water knockout and the filter meanswith ultra-sonic demulsifying vibrations at approximately the cavitationlevel.

References Cited by the Examiner UNITED STATES PATENTS 2,257,997 10/41Barnes. 2,384,222 9/45 Walker 210- X 2,457,959 1/49 Walker 210-258 X2,578,505 12/51 Carlin 259 126 2,7 02,691 2/55 Virmani. 2,717,768 9/55Carpentier. 2,864,502 12/58 May 2lO--19 X FOREIGN PATENTS 862,543 4/53Germany.

OTHER REFERENCES Alexander, R; Mfg. Chemist, January 1951 (XX'II, 1),pp. 5-6.

MORRIS O. WOLK, Primary Examiner.

CARL F. KRAFT, GEORGE D. MITCHELL,

' Examiners.

1. APPARATUS FOR THE SEPARATION OF HYDROCARBON EMULSIONS COMPRISING AHEATER FOR RECEIVING HYDROCARBON EMULSIONS, MEANS IN THE HEATER FORBREAKING THE EMULSIONS TO A SUBSTANTIAL EXTENT, A FILTER TANK, MEANSCONNECTING THE HEATER TANK WITH THE FILTER TANK FOR FLOW OF OIL FROM THEHEATER TANK TO THE FILTER TANK, MENS IN THE FILTER TANK FOR FILTERINGWATER FROM THE OIL THEREIN, AND MEANS CONNECTED BETWEEN THE TWO TANKSFOR TREATING THE PRODUCTS RECEIVED FROM THE HEATER TANK WITH ULTRA-SONICDEMULSIFYING VIBRATIONS AT APPROXIMATELY THE CAVITATION LEVEL IN THEINSTANT VOLUME OF OIL FLOWING FROM THE HEATER TANK TO THE FILTER TANK.